AUTO ARC 255 User manual

AUTO
ARCS
June 1996
Effective
With
Serial
No.
KG171
523
Form:
OM-157066E
OWNERS
MANUAL

Read
and
follow
these instructions
and
all
safety
blocks
carefully.

Have
only
trained
and
qualified
persons
install,
operate,
or
service this unit.
ii~J

Give this
manual
to
the
operator.
.

For
help,
call
your
distributor
-.

Call
your
distributor
if
you
do
not
understand
the
directions.
U
or:
MILLER Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912 414-734-9821
Auto
Arcfi
Model
255

DC/CV
Welding
Power Source/Wire
Feeder

For GMAW And FCAW
Welding
 Uses
.023

.045
Hard
Wire
And .030

.045
Flux
Cored
Wire

200
Amperes,
28
Volts
DC At
60%
Duty Cycle

Uses
Single-Phase
Input
Power

Overheating
And
Motor
Overload Protection

Includes
Gun
And
Shielding
Gas
Valve
auto_arc
7/93
ST-157 072-A
PRINTED
IN
USA

LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of KD
or
newer)
This
limited
warranty
supersedes
all
previous
manufscturers
warranties end is exclusive
with
no
other
guarsntees
or
wsrrsnties
expressed
or
implied.
LIMITED
WARRANTY

Subject
to
the
temis
end conditions
below,
wsrrsnts
to
its

MPG Guns/TIG Torches
originsl
reteil
purchsser
thst
new
equipment
sold
sfter
the
effective
dste of this
lim-
APT
~PCUT
&
PLAZCUT Model
Plssma
Cuffing
Torches
lted
wsrrsnty
is free
of defects in msterisl end
workmsnship
at
the time it is
shipped
*
Rweote
Controls
from
factory
THIS
WARRANTY IS
EXPRESSLY
IN
LIEU
OF
ALL
OThER
WAR
RANTIES,
EXPRESS OR
IMPLIED,
INCLUDING THE WARRANTIES OF MER-
AccessorY
Kits
CHANTABIUTY
AND
FITNESS.
*
Replscsment
Psrts
Within the
wsrrshty
periods
listed
below,
manufsctumrwill
repsiror replsce
sny
wsr-
Umited
Wsrranty
shell
not
spply
to:
rented
psits orcomponents
thstfsit due
to
such
defects In msterisl
orworlonsnship.
Msnufscturer
must
be
notified
in
writing
within
thirly
(30)
dsys
of
such
defect
or
fail
ure,
st
which tIme
manufscturer
will
provide
instructions
on
the
wsrranty
clsim
pro
cedures
to
be
followed.
Msnufscturer ehslt honor
wsrrsnty
clsims
on
wsrrsnted
equipment
listed below
in
2.
the
event
of
such
s
failure
within the
werranty
time
periods.
All
wsrrsrrty
time
periods
stsrt
on
the dste thst
the
equipment
wss
delivered
to
the
original
retell
purchsser,
or
one
yesr
after
the
equipment
is
sent to
a
North American distributor
or
eighteen
months efter
the
equipment
is
sent to
en
Intemationsl distributor.
1. 5YesrsPsrts3YeamLabor

Original
main
power
rectiftem

Inverters
(input
end
output
rectifiers
onlly)
2. 3
Years

Parts end
Lsbor

Transfomier/Rectlfier Power Sources
Ptsams Arc
Cuffing
Power
Sources

Semi-Automatic end Automstic Wire
Feeders

Inverter Power
Supplies

Intellitig

Robots
(1
yesr
labor)
3.
2
Years Parts
end
Labor

Engine
Driven
Welding
Generetom
(NOTE: Engines
ere
werranted
seperstely by
the
engine msnufacturer.)
*
Air
Compressors
4. 1 Year

Parts end Labor

Motor
Driven Guns

Process
Controllers
*
IHPS Power
Sources

Water Coolant
Systems
HF
Units

Grate

Spot
Welders

Load
Banks

SDXTrensformers

Running
Gear/Trailers

Plasma
Cutting
Torches
(except
APT
ZIPCUT
&
PLAZCUT
Models)

Tecumseh
Engines

Deutz
Engines
(outside
North
America)

Field
Options
(NOTE:
Field
options
em
covered under the limited
warranty
for the
re
maining
warranty
period
of
the
product
they
are
installed
in,
ortor
a
mini
mum
of
one
yesr

whIchever Is
greater.)
6 Months

Batteries
90
Days

Parts
and
Labor
Consumable
components;
such
as
contact
tips,
cuffing
nozzles,
contactom
and
releya
or
paris
that
fail
due
to
normal
wear.
Equipment
that has been
modified
by
any
party
other
then
manufacturer,
or
equlpmentthst
hen been
improperly
Installed,
improperly
opersted
or
misused
based
upon
industry
standards,
or
equipment
which
hes
not
had
reasonable
end
necessary
meintenance,
or
equipment
which has been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MANUFACTURERS PRODUCTS ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMERCIAL/iNDUSTRIAL
USERS AND PERSONS
TRAINED
AND EXPE
RIENCED
IN THE USE AND MAINTENANCE OF WELDING
EGUIPMENT.
In
the
event
of
a
warranty
claim covered
by
this
warranty,
the
exclusive
mmedies
ahall
be,
at
manufacturers
option: (1) repair or(2) replacement;
or,
where authorized
in
writing
by
manufacturer
in
appropriate
cases,
(3)
the
reasonable
coat
of
repair
or
replacement
at
an
authoflzed service
station;
or
(4)
payment
of
or
credit for
the
pur
chase
price
hess
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers risk
and
expense.
Manufacturers
option
of
repair
or
replace
ment
will be
F.O.B.,
Factory
at
Appleton.
Wisconsin,
or
FOB.
at
an
authorized
ser
vice
facility
as
determined
by
manufecturer. Therefore
no
compensation
or
reim
bursement tsr
transportation
coats
of
any
kind will be allowed.
TO ThE EXTENT PERMIrrED BY
LAW,
THE REMEDIES
PROVIDED
HEREIN
ARE ThE SDLE AND EXCLUSIVE REMEDIES.
IN
NO EVENT
SHALL
MANUFAC
TIJRER
BE UABLE
FOR
DIRECT,
INDIRECT, SPECIAL
INCIDENTAL
OR
CON
SEOUENTIAL DAMAGES
(INCLUDING
LOSS OF
PROFIT),
WHEThER
BASED
ON
CONTRACt
TORT
OR
ANY
OThER LEGAL ThEORY.
ANY
EXPRESS
WARRANTY
NOT PROVIDED
HEREIN AND
ANY
IMPLIED WAR
RANTY,
GUARANTY OR REPRESENTATION AS TO
PERFORMANCE,
AND ANY
REMEDY
FOR
BREACH
OF
CONTRACT TORT OR
ANY
OThER LEGAL
ThEORY
WHICH,
BUT
FOR THIS
PROVISION,
MIGHT ARISE
BY
IMPLICATION,
OPERATION OF
LAW,
CUSTOM OF
TRADE
OR COURSE
OF
DEALING,
IN
CLUDING
ANY IMPLIED
WARRANTY OF
MERCHANTABIUTY
OR
FITNESS
FOR PARTICULAR
PURPOSE,
WITh
RESPECT TO
ANY
AND
ALL
EOUIPMENT
FURNISHED BY MANUFACTURER IS
EXCLUDED
AND
DISCLAIMED
BY
MAN
UFACTURER.
Some
states
In
the
U.S.A.
do
not
allow
limitations
of
how
tong
an
implied
werrenty
lasts,
or
the exclusion
of
incidental, indirect,
special
or
consequential
damages,
so
the
above limitation
or
exclusion
may
not
apply
to
you.
This
warrenty
provides
ape
cific
legal rights,
and
other
rights
may
be
available,
but
may vary
from
state
to
state.
In
Canade,
legislation
In
some
provlncas provides
for certain
additional warranties
or
remedies other than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and exclusions
set out
above
may
not
apply.
This
LimIted
Warranty
prsvidea
epecific
legal rights,
end other
rights
may
be
available,
but
may
vary
from
province
to
province.
-I-.
1.
Itemafumlshed
by
manufacturer,
but manufactured
by
others,
auth
as
engines
ortrsde
accessories.
These items
are
covered
by
the
manuf acturers
warranty,
if
any.
5.
{.
RECEIVING-HANDLING
Before
unpacking equipment,
check
carton
for
any
damage
that
may
have occurred
during shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier. Assistance
for
filing
or
settling
claims
may
be obtained
from
distributor
and/or
equipment
manufacturers
Transportation Department.
When
requesting
information about this
equipment, always provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Numberof
your
unit. The information is located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No,
Date of
Purchase
brand_wer
3/96

AUTO
ARCJ
June1996
Form:
OM-157066E
Effective
With
Serial
No.
KG171
523
OWNERS
MANUAL
U
Read and follow
these
instructions and all

Give
this manual
to
the
operator.

safety
blocks
carefully.
Have
only
trained
and
qualified
persons
.
U
install,
operate,
or
service this unit.
Call
your
distributor if
you
do
not
understand
the directions.
1I~fl


U
For
help,
call
your
distributor
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
Auto
Arcfi
Model
255

DC/CV
Welding
Power Source/Wire Feeder

For
GMAW And FCAW
Welding

Uses
.023

.045 Hard Wire
And
.030

.045
Flux
Cored Wire

200
Amperes,
28
Volts DC At
60%
Duty Cycle

Uses
Single-Phase Input
Power

Overheating
And Motor Overload Protection

Includes
Gun And
Shielding
Gas
Valve
autoam
7/93

ST-i
57 072-A
PRINTED
IN
USA

LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial number
praface
of KD
or
newer)
This limited
warranty
supemedes
all
previous
manufacturem
warranties end is exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY

Subject
to
the
terms
end
conditions
below,
warrants to
its

MIG
Guns/TIG Torches
original
retail
purchaser
thst
new
equipment
sold
after
the
effective date
of
this
tim-
*
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
ited
warranty
is free
of defects
in
material and
workmanship
at
the
time
it is
shipped
Remote
C
from
factory
THIS
WARRANTY
IS EXPRESSLY
IN
LIEU
OF ALL
OTHER
WAR-
on ma
RANTIES,
EXPRESS OR
IMPLIED,
INCLUDING
THE
WARRANTIES OF
MER-
Accessory
Kits
CHANTABILITY
AND
FITNESS.
*
Replacement
Parts
Within the
warranty
periods
listed
below,
manufacturerwill
repairor replace
anywar-
Umited
Warranty
ahall
not
apply
to:
rented
parts
orcomponenta
that
fail due
to
such
defects
in
material
orworkmanahip.
Manufacturer
must
be
notified in
writing
within
thirty (30) days
of
such
defect
or
fail-
1.
Itemafumished
by
manufacturer,
but
manufactured
by
othem,
such
as
engines
ure,
at
which time
manufacturer
will
provide
instructions
on
the
warranty
claim
pro-
ortrade accessories.
These items
am
covered
bythe
manufacturerawarranty,
cedures
to
be
followed.
-
if
any.
Manufacturer shall
honor
warranty
claims
on
warranted
equipment
listed below
in
2.
the
event
of
such
a
failure within the
warrentytime periods.
All
warrantytime
periods
start
on
the
date
that the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent to
a
North American
distributor
or
eighteen
~
months
after
the
equipment
is
aent to
en
International distributor.
1.
5veamParts3YeareLsbor
*
Original
main
power
rectiflere

Invertere
(input
and
output
rectifiera
onlly)
2. 3
Yeam

Parts
and
Labor

Transformer/Rectifier
Power
Sources
*
Plasma Arc
Cutting
Power Sources
*
Semi-Automatic
and
Automatic Wire Feedera

Inverter
Power
Supplies

Intellitig
*
Robots
(1
year
labor)
3.
2 Yeam

Parts and Labor
*
Engine
Driven
Welding
Generatore
(NOTE: Engines
are
warranted
separately by
the
engine
manufacturer.)

Air
Compreasora
4. 1
YearParts and Labor
*
Motor
Driven Guns
*
Process
Controllera
*
IHPS
Power Sources
Water Coolant
Systems
*
HF
Units

Grids
*
Spot
Weldera
Load
Banks

SDXTmnsformem
*
Running
Gearfrrailera

Plasma
Cutting
Torchea
(except
APT
ZIPCUT
& PLAZCUT
Models)
*
Tecumseh
Engines

Deutz
Engines
(outside
North
America)
*
Field
Options
(NOTE:
Field
options
are
covered under the
limited
warranty
for
the
re
maining
warranty
period
of
the
product
they
are
installed
in,
orfor
a
mini
mum
of
one
year

whichever is
greater.)
6 Months

Batteries
90
Days

Parts and
Labor
Consumable
components;
such
as
contact
tips, cutting
nozzles,
contactora
and
relays
or
parts
that
fail
due
to
normal
wear.
Equipment
that has been
modified
by
any
party
other than
manufacturer,
or
equipmentthat
has been
improperiy
installed,
improperiy
opemted
or
misused
based upon
industry
standards,
or
equipment
which has
not
had reasonable
and
necassary
maintenance,
or
equipment
which has been
used for
operation
outside
of
the
specifications
for the
equipment.
MANUFACTURERS PRODUCTS
ARE
INTENDED
FOR PURCHASE
AND
USE
BY
COMMERCIAL/INDUSTRIAL USERS
AND
PERSONS
TRAINED AND EXPE
RIENCED IN THE
USE
AND
MAINTENANCE OF
WELDING EQUIPMENT
In the
event
of
a
warranty
claim covered
by
this
warranty,
the exclusive
remedies
shall
be,
at
manufactumra
option:
(1)
repair~
or(2) replacement;
or,
where authorized
in
writing by
manufacturer
in
appropriate
cases,
(3)
the reasonable
coat
of
repair
or
replacement
at
an
authorized
asrvice
atation;
or
(4)
payment
of
or
credit
for
the
pur
chase
price (lees
reasonable
depreciation
based
upon
actual
use)
upon
return
of the
goods
at
customers risk and
expense.
Manufacturers
option
of
repair
or
replace
ment
will be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
an
authorized
asr
vice
facility
as
determined
by
manufacturer.
Therefore
no
compensation
or
reim
buraement for
transportation
costs
of
any
kind will
be
allowed.
TO THE EXTENT PERMITTED
BY
LAW,
THE
REMEDIES PROVIDED
HEREIN
ARETHE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO EVENTSHALL
MANUFAC
TURER BE LIABLE
FOR
DIRECT,
INDIRECT,
SPECtAL,
INCIDENTAL OR
CON
SEQUENTIAL DAMAGES
(INCLUDING
LOSS OF
PROFIT),
WHETHER
BASED
ON
CONTRACT,
TORT
OR
ANY
OTHER LEGAL
THEORY.
ANY EXPRESS WARRANTY
NOT PROVIDED
HEREIN ANDANY
IMPLIED WAR
RANTY,
GUARANTY OR
REPRESENTA11ON
AS TO
PERFORMANCE,
AND ANY
REMEDY
FOR BREACH OF CONTRACT
TORT
OR ANY OTHER
LEGAL
THEORY
WHICH,
BUTFORTHIS
PROVISION,
MIGHT ARISE
BY
IMPLICATiON,
OPERATiON OF
LAW,
CUSTOM
OF TRADE
OR COURSE OF
DEALING,
IN
CLUDING ANY IMPLIED WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT TO
ANY
AND ALL
EQUIPMENT
FURNISHED
BY
MANUFACTURER
IS EXCLUDED
AND
DISCLAIMED
BY
MAN
UFACTURER.
Some
states
in the
U.S.A.
do
not
allow limitationa
of
how
long
an
implied
warranty
lasts,
or
the
exclusion of
incidental, indirect,
special
or
consequential damages,
so
the above limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights
may
be
available,
but
may vary
from
state
to state.
In
Canada,
legislation
in
some
provinces provides
for
certain additional
warranties
or
remedies other than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations and
exclusions
set
out
above
may
not
apply.
This Limited
Warranty provides specific legal rights,
and other
rights
may
be
available,
but
may
vary
from
province
to
province.
a. I 
5.
.E~
r
J
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have occurred
during
shipment.
File
any
Claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance for
filing
or
settling
claims
may
be obtained
from distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information about
this
equipment, always provide
Model
Designation
and Serial
or
Style
Number.
Use the
following
spaces
to
record
Model
Designation
and Serial
or
Style
Numberof
your
unit.
The information
is located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of Purchase
brand_war
3/96

ARC
WELDING SAFETY
PRECAUTIONS
ELECTRIC
SHOCK
can
kill.
Touching
live electncal
parts
can cause
fatal
shocks
or severe
bums. The
electrode
and work
circuit
is
electrically
live whenever the
output
is
on.
The
input
power
circuit and machine internal
circuits
are
also
live when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and all metal
parts
touchin9
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch live
electrical
parts.
2. Wear
dry,
hole-free
insulating gloves
and
body
protection.
3.
Insulate
yourself
from work and
ground using dry insulating
mats
or covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
5.
Properiy
install
and
ground
this
equipment
according
to
its
Owners Manual
and
national,
state,
and local
codes.
Turn off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
wrap
cables
around
your
body.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
Do
not
touch
electrode
while
in
contact
with
the
work
(ground)
circuit.
11.
Use
only
well-maintained
equipment. Repair
or
replace
damaged
parts
at
once.
12. Wear
a
safety
harness
to
prevent
falling
if
working
above floor
level.
13.
Keep
all
panels
and
covers
securely
in
place.
1.
Wear
approved
face
shield
or
safety goggles.
Side
shields
recommended.
AA
WARNING
ARC
WELDING
can
be hazardous.
PROTECT YOURSELF
AND
OTHERS
FROM
POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER
WEARERS
KEEP
AWAY UNTIL CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain hazards
occurs.
Welding
is safe
when
precautions
are
taken. The
safety
information
given
below is
only
a
summary
of
the
more
complete
safety
information that will be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE ALL
INSTALLATION, OPERATION, MAINTENANCE,
AND
REPAIR
WORK PERFORMED ONLY
BY
QUALIFIED
PEOPLE.
6.
7.
8.
9.
10.
,~,,
~
-9r.~i
-.
ARC RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet
fitted with
a
proper
shade of filter
(see
NOISE
can
damage
hearing.
ANSI
Z49.
1
listed in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Arc
rays
from the
welding
process
produce
intense
2. Wear
approved
safety glasses.
Side
shields recommended.
heat and
strong
ultraviolet
rays
that
can
bum
eyes
3. Use
protective
screens
or
barriers
to
protect
others from flash
and skin. Noise
from
some
processes
can
damage
and
glare;
warn
others
not to
watch the
arc.
earing.
4.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Use
approved
ear
plugs
or ear
muffs if noise level is
high.
FUMES
AND
GASES
can
be hazardous
5.
Work
in
a
confined
space
only
if
it
is well
ventilated,
or
while
to
your
health.
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
Welding
produces
fumes
and
gases.
Breathing
welding
can
displace
air
causing injury
or
death. Be
sure
the

these
fumes
and
gases
can
be hazardous
to
your
breathing
air is
safe.
health.
6. Do
not
weld
in
locations
near
degreasing, cleaning,
or
spraying
operations.
The
heat
and
rays
of the
arc can
react
with
vapors
to
1.
Keep
your
head
out
of
the
fumes. Do
not
breathe the
fumes.
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use an
approved
air-supplied respirator.
cadmium
plated
steel,
unless the
coating
is removed
from
the
4.
Read the
Material
Safety
Data Sheets
(MSDSs)
and the
weld
area,
the
area
is well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals, consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and cleaners,
containing
these
elements
can
give
off toxic fumes
if
welded.
WELDING
can cause
fire
or
explosion.
5.
Watch for
fire,
and
keep
a
fire
extinguisher nearby.
Sparks
and
spatter fly
oft from
the
welding
arc.
The
flying
sparks
and hot
metal,
weld
spatter,
hot
6.
Be
aware
that
welding
on a
ceiling,
floor,
bulkhead,
or
partition
can cause
fire
on
the
hidden
side.
workpiece,
and
hot
equipment
can cause
fires
and
burns.
Accidental
contact
of electrode
or
welding
wire
to
metal
objects
can cause
sparks,
overheating,
or
fire.
7.
8.
Do
not
weld
on
closed
containers such
as
tanks
or
drums.
Connect
work
cable
to
the work
as
close
to
the
welding
area as
practical
to
prevent
welding
current
from
traveling long,
possibly
unknown
paths
and
causing
electric shock and fire
1.
Protect
yourself
and
others from
flying sparks
and hot metal,
hazards.
2.
Do
not
weld where
flying
sparks
can
strike
flammable
material.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
3. Remove all
flammables
within 35
ft
(10.7 m)
of
the
welding
arc.
10.
Remove stick
electrode
from holder
or
cut
off
welding
wire
at
If
this is
not
possible,
tightly
cover
them
with
approved
covers,
contact
tip
when
not
in
use.
4.
Be alert
that
welding
sparks
and hot materials
from
welding
can
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
easily
go
through
small
cracks and
openings
to
adjacent
areas.
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
FLYING SPARKS AND HOT METAL
can
cause
injury.
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
2.
Wear
proper
body
protection
to
protect
skin.

CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install and
secure
cylinders
in
an
upright
position
by chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
____________

3.
Keep cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from valve outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
Read and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed in
Safety
Standards.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.i,
from
American
Welding
Society,
550
NW.
LeJeune
Rd,
Miami
FL 33126
Safetyand
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C. 20402.
Recommended
Safe
Practices
for the
Preparation
for
Welding
and
Cutting
of Containers
That
Have
Held Hazardous
Substances,
American
Weld
ing
Society
Standard
AWS
F4.i,
from American
Welding
Society,
550
N.W. LeJeune
Ad,
Miami,
FL 33126
National
Electrical
Code,
NFPA Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code for
Safety
in
Welding
and
Cutting,
CSA Standard
Wi
17.2,
from Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI Standard Z87.
1
,from
American National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
Si
B,
from
National
Fire Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
EMF
INFORMATION
TABLE
OF CONTENTS
SECTION
1
-
SAFETY INFORMATION
1
SECTION
2
SPECIFICATIONS
1
2-1.
Volt-Ampere
Curves
2
2-2.
Duty Cycle
2
SECTION
3
INSTALLATION
3
3-1.
Installing
Work
Clamp
3
3-2.
Installing
Gas
Supply
4
3-3.
Gun
Polarity
Connections
5
3-4.
Installing
Drive Rolls And
Welding
Gun
5
3-5.
Connecting Input
Power
6
3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension...
.
8
3-7.
Threading
And
Feeding
Welding
Wire
8
SECTION
4
OPERATION
10
SECTION 5MAINTENANCE
&
TROUBLESHOOTING
12
5-1.
Routine Maintenance
12
5-2.
Overload
Protection
13
5-3.
Wire
Drive
Assembly
Maintenance
14
5-4.
Gun Maintenance
15
5-5.
Troubleshooting
16
SECTION
6
ELECTRICAL
DIAGRAM
17
SECTION
7
PARTS
LIST
18
Figure
7-1.
Main
Assembly
18
Figure
7-2.
MWG-21C
Gun
19
Figure
7-3.
Baffle
w/Cmpts
20
NOTE
~
Magnetic
Fields
Considerations
About
Welding
And The
Effects Of
Low
Frequency
Electric
And
The
following
is
a
quotation
from the
General Conclusions Section
of the
U.S.
Congress,
Office of
Technology
Assessment,
Biological
Effects
of Power
Frequency
Electric
&
Magnetic
Fields

Background
Paper,
OTA-BP-E-53
(Washington,
DC: U.S.
Government
Printing
Office,
May
1989):..
.
there is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular level and
from
studies with animals
and
people
which
clearly
establish
that low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological systems.
While
most
of
this work is
of
very
high
quality,
the
results
are
complex.
Current scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions about
questions
of possible
risk
or
to
offer
clear
science-based advice
on
strategies
to
minimize
or
avoid
potential
risks.
To reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1.
Keep
cables
close
together by twisting
or
taping
them.
2.
Arrange
cables
to
one
side and
away
from
the
operator.
3.
Do
not
coil
or
drape
cables around
the
body.
4.
Keep
welding
power
source
and cables
as
far
away
as
practical.
About
Pacemakers:
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
The
above
procedures
are
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
modlo
1
4/93

SECTION
1
-
SAFETY
INFORMATION
OM-157066E6/96
modl.1
2/93
a
CAUTION

Read
all
safety
messages
throughout
this
manual.
U
Obey
all
safety
messages
to
avoid
injury.
U
Learn the
meaning
of WARNING and
CAUTION.
1
Safety
Alert
Symbol
1
22
2
SignalWord
WARNING
means
possible
death
P
.
or
serious
injury
can
happen.
!~!i!t~
:1~II~eU
-3
CAUTION
means
possible
minor
ELECTRIC SHOCK
can
kiII.f~

MOVING PARTS
can
injure,
injury
or
equipment
damage
can
~%

Do
not
touch live
electrical
parts.

Keep
away
from
moving
parts,
happen.

Disconnect
input
power
before
4

Keep
all
panels
and
covers
closed
3Statement
Of
Hazard
And
installing
or
servicing,
when
operating.
Result
/ 4
Safety
Instructions To
Avoid
5
Hazard
5
Hazard
Symbol (If
Available)
6
Safety
Banner
~
~
~
~E~r~cSe=t
of
Read
safety
blocks
for
each
sym
7
NOTE
NOTE
~
Turn Off switch when
using high
frequency.
Special
instructions
for
best
oper
ation

not
related
to
safety.
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Welding
Power Source
Specifications
Description
Type
Of
Output
Direct
Current/Constant
Voltage
(DC/CV)
Rated Weld
Output
200
Amperes,
28
Volts
DC,
60%
Duty Cycle
(See
Section
2-2)
Type
Of
Input
Power
Single-Phase;
60
Hz;
At
200
Or
230
Volts
AC
Input Amperes
At
Rated
Output
46
A
At
200
V,
40
A
At
230
V
Maximum
Input
Amperes
While
Idling
1.2
A
At 200
V,
1
A
At 230
V
KVNKW
Used
At
Rated
Output
9.5
kVAI8.3
kW
Maximum KVNKW Used
While
Idling
0.24 kVNO.17 kW
Max.
Open-Circuit
Voltage
42
Volts
DC
Control Circuit
Voltage
At Gun 24 Volts
DC
Welding
Processes
Gas
Metal
Arc
(GMAW)
And Flux Cored Arc
Welding (FCAW)
Calculated
Speed
Range
At No Load 128
To 1051
ipm
(3.2
To 266.9
mpm)
Wire
Diameter
Range
.030 To
.045
in
(0.8
To
1.1
mm)
Flux
Cored
Wire;
.023 To
.045
in
(0.6
To
1.1
mm)
Hard
Wire
Overall Dimensions
Length:
30-1/4
in
(768 mm);
Width: 19
in
(483
mm);
Height:
37
in
(940
mm)
Weight
Net:
225
lb
(102 kg);
Ship:
271 lb
(123 kg)
Welding
Gun
Rated
Output (Air Cooled)
200
Amperes
At 60%
Duty
Cycle
Using
CO2 Shielding
Gas
(See
Section
2-2)
Cable
Length
15
ft
(4.6 m)
OM-157
066
Page
1

2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
4A
CAUTION
~.
~-
~-
REED
OIJrRJT-1
Figure
2-2.
Duty Cycle
The
volt-ampere
curves
show the
50
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of other
settings
fall be
tween
the
curves
shown.
~Iz~
g2o
0
I
I I
I
I
0
25
50
75 100
125
150 175
200
225
DC AMPERES
ssbl.1 10/91
SB-049424-D
WELDING
LONGER THAN
RATED
DUTY CYCLE
can
damage
unit
or
gun
and
void
warranty.

Do
n
ot
weld
at
rated
load
longer
than shown
below.
wfwam8.2
8/93
0
Definition
~
Duty Cycle
is
percentage
of
10
10
weld
at
rated
load
without
over-
minutes that unit
or
gun
can
Minutes
heating.
UNIT
60%
Duty
Cycle
At
200
Amperes
g
6
Minutes
Welding
4
Minutes
Resting
Chart
GUN
6 minutes
Welding
4
minutes
Resting
w
-


  
- -    
100



- - -
.i
 - -
00
00 40 00 00
JO 1010100
~fGUN
60%
Duty
Cycle
At 180
Amperes
Using
Mixed Gas
X DJTY
~
6
minutes
Welding
4
minutes
Resting
sbl.3
8/93SB-150
215
OM-157
066
Page
2

3-1.
Installing
Work
Clamp
Figure
3-1.
Installing
Work
Clamp
SECTION
3-
INSTALLATION
5
1
Work
Cable
2 Boot
Slide
boot
onto
work cable.
Route
cable
out
front
panel opening
from
inside.
3
Negative
() Output
Terminal
Connect cable
to
terminal and
cov
er
connection
with boot.
4
Hardware
4
5
Work
Clamp
Route
cable
through
clamp
handle
and
secure
to
top
of
clamp
with
hardware.
Close door.
Tools Needed:
r
1/2,
3/4
in
Ref. ST-154
630-A
OM-157
066
Page
3

3-2.
Installing
Gas
Supply
a
WARNING
CYLINDERS
can
explode
if
damaged.

Keep cylinders
away
from
welding
and
other
electrical
circuits.

Never touch
cylinder
with
welding
electrode.

Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
-
~..
BUILDUP OF SHIELDING GAS
can
harm
health
or
kill.
1r

Shut off
shielding
gas
supply
when
not
in
use.
wam4.1
9/91
1
Cylinder
Bracket
2
S-Hook
Crimp
between
small hole
in brack
et
and chain.
3 Chain
4
Snap
Crimp
onto
open
end
of chain.
Obtain
gas
cylinder
and chain
to
running
gear.
5
Cap
6
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow
blows dust
and
dirt from
valve.
Close
valve.
7
Cylinder
8
Regulator/Flowmeter
Install
so
face
is
vertical.
9 Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads.
Obtain and
install
gas
hose.
Tools Needed:
5/8,1-1/Bin
ssb3.1
-
5/94

ST-154 623 / ST-158 697-A
10 Flow
Adjust
Typical
flow
rate
is 20 cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
Make
sure
flow
adjust
is closed
when
opening cylinder
to
avoid
damage
to
the
flowmeter.
11
CO2
Adapter
12
0-Ring
Install
adapter
with
0-nng
between
regulator/flowmeter
and
CO2
cylinder.
Figure
3-2.
Typical
Regulator/Flowmeter
Installation
OM-157
066
Page
4

3-3.
Gun
Polarity
Connections
A~
WARNING
ELECTRIC SHOCK
can
kill.

Do
not
touch live electrical
parts.

Turn
Off
welding
power
source,
and disconnect
input
power
before
inspecting
or
installing.
3-4.
Installing
Drive
Rolls And
Welding
Gun
swaml.1
2./93
Shown As
Shipped

Set
For
Electrode
Positive
(DCEP)
For
Solid Steel Or
Aluminum
Wires
(GMAW
Process).
Wire Drive
Assembly
Lead
To
Positive
(+) Output
Terminal
5
Work
Clamp
Lead To
Negative
()
Output
Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead
Connections

For Electrode
Negative (DCEN)
For
Flux
Cored
Wires
(FCAW
Process).
Drive
Assembly
Becomes
Negative
S-14.4 449-C
1
Polarity Changeover
Label
2
Wire
Drive
Assembly
3
Positive
(+) Output
Terminal
4
Negative
()
Output
Terminal
Always
read and
follow
wire
man
ufacturers
recommended
polarity.
5
Circuit
Breaker
CB1
(see
Section
5-2).
Tools Needed:
~z=Z~
3/4,11/l6in
Ref.
ST-153
874-B
Figure
3-3.
Gun
Polarity
Connections
5
1
Pressure
Adjustment
2
Pressure
Assembly
3
Drive
Roll
4
Securing
Screw
Install
correct
drive roll
for
wire size
and
type
using
supplied
screws.
5 Wire
Drive
Assembly
6
Gun
Securing
Knob
7
Gun
End
Loosen
securing
knob. Insert
gun
end
through
opening
until it bot
toms
against
drive
assembly.
lighten
knob.
8
Gun
Trigger Plug
Insert
into
receptacle,
and
tighten
threaded
collar.
Close
pressure
assembly.
Close
door.
ST-
154 621 /
Ref. ST-154
624-A
.7
Tools
Needed:
6
Figure
3-4.
Gun
Connections
OM-1
57066
Page
5

3-5. Connecting
Input
Power
A.
Positioning Jumper
Links
Figure
3-5.
Input
Voltage
Jumper
Links
Location
Jumper
links
allow
operation
on
different
input voltages
and
are
factory
set
for the
highest
input
voltage.
Check
input voltage
available
at
site.
1
Input Voltage
Label
a
WARNING
ELECTRIC SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.

Have
only
qualified
persons
install unit.

Installation
must
meet
National
Electrical Code
and all other
codes.
swam3.1
2193
200
VOLTS
230
VOLTS
S-153
980
I
Look
at
jumper
links
and
compare
link
position
with
applicable
label.
2
Screw
3
Access Door
To
change
link
position,
remove
screw
and
pivot
door
up.
4
Input
Voltage
Jumper
Links
Location
Move
links
to
match
input
voltage.
For
example,
use
200 volts
posi
tion when 200
volts
input
power
is
available.
Close
door
and
secure
with
screw.
Close side door.
Tools
Needed:
c::~::rJ==iJ
3/8
in
ssb5.i 2192 / Ref. ST-i
54
626-B
/ Ref. ST-i54 628-B
OM-157 066
Page
6

B.
Connecting
Input
Power
Have
only qualified
persons
make
this installation.
1
Line Disconnect
Device Of
Proper
Rating
2
230 Volts AC
Wall
Receptacle
3
Input
Conductors
4
Grounding
Conductor
Select
size and
length
using
Table
3-1.
Conductor
rating
must
comply
with
national,
state,
and
local electrical
codes.
Install
and
connect
grounding
conductor and
input
conductors in
conduit
or
equivalent
between
wall
receptacle
and
deenergized
line
disconnect device.
Connect
grounding
conductor
first,
then line
input
conductors.
Be
sure
grounding
conductor
goes
to
an
earth
ground.
5
Overcurrent
Protection
Select
type
and
size
using
Table
3-1. Install
into
deenergized
line disconnect
device
(fused
dis
connect
switch
shown).
6
Input
Power
Plug
Tum oft unit
Power
switch,
and
connect
plug
to
wall
receptacle.
ssb2.2
12/94

Ref. ST-i
54
619-B /
Ret. ST-i
49 405-B
Figure
3-6.
Input
Power
Connections
Table
3-1.
Electrical Service
Requirements*
Input
Voltage
200
230
Input Amperes
At Rated
Output
46
40
Recommended Standard Fuse
Or
Circuit Breaker
Rating
In
Amperes
70
60
Mm
Input
Conductor
Size
In
AWGIKcmiI
88
Max
Input
Conductor
Length
In
Feet
(Meters)
89
(27)
117
(36)
Mm
Grounding
Conductor
Size
In
AWG/Kcmil
810
These
values
are
calculated from
the
1996 edition of the
National
Electrical Code
(NEC).
S-0092-H
5
3
Tools Needed:
OM-157
066
Page
7

3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
Figure
3-7.
Installing
Wire
Spool
And
Adjusting
Hub Tension
3-7.
Threading
And
Feeding
Welding
Wire
a
WARNING
CYLINDERS
can
explode
if
damaged.

Keep
cylinders
away
from
welding
and other
electrical circuits.
Never touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
other
stationary
support.
ELECTRIC
SHOCK
can
kill.

Do
not
touch live electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
a
metal
parts
touching
the
welding
wire
are
electricall
live
when
welding
or
feeding
wire
using
gun
trigger.
WELDING WIRE
can
cause
puncture
wounds.

Do
not
press gun
trigger
until instructed
to
do
so.

Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal when
threading
welding
wire.
HOT SURFACES
can
burn
skin.

Allow
gun
to
cool
before
touching.
swarn5.1
10/91 Iswam2.1
9191
1
Turn
Off
unit.
1
Wire
Spool
2
Gun
Contact
lip
If
necessary,
cut
welding
wire
off
at
contact
tip,
and
retract
wire
onto
spool
and
secure.
3
Retaining
Ring
4
Compression
Spring
Remove
ring
and
pull
off
spool.
Compression
spring
is used
with
8
in
(200
mm) spools.
5
Hub
6
Hub Pin
Slide
spool
onto
hub
so
wire
feeds
off
bottom.
Turn
spool
until
hub
pin
fits hole
in
back
of
spool.
Reinstall
retaining
ring.
7
Hub
Tension
Nut
Grasp spool
in
one
hand
and
turn
while
using
a
wrench
to
adjust
hub
tension
nut.
When
a
slight
force
is
needed
to
turn
spool,
tension is
set.
Thread
welding
wire
(see
Section
3-7).
Close
door.
Tools
Needed:
~
15/l6in
Ref.
ST-154 626-B
/ Ref. ST-072
573-B
OM-157
066
Page
8

1
Wire
Spool
2
Welding
Wire
3 Inlet Wire
Guide
4
Pressure
Adjustment
Knob
5
Pressure
Assembly
Drive Roll
Outlet Wire Guide
Gun Conduit Cable
Lay
gun
cable
out
straight.
Close
and
tighten
pressure
assembly,
and let
go
of
wire.
/
Press
gun
trigger
until wire
comes
out
of
gun.
Reinstall
contact
tip
and nozzle.
Remove
gun
nozzle
and
contact
tip.
Feed wire
to
check drive roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
I
Cut
off
wire.
Close
and latch
door.
Figure
3-8.
Threading
And
Feeding Welding
Wire
ST-800
739-A /
ST.154
251
/
S-0627-A
6
7
8
2 3 6
7
Hold wire
tightly
to
keep
it
from
unraveling.
Open
pressure
assembly.
Pull
and
hold
wire;
cut
oft
end.
Push wire thru
guides
into
gun;
continue
to
hold wire.
-4
=~
I~
-4~
00FF
Set
switch.
El
I
I
OM-1
57
066
Page
9

SECTION
4-
OPERATION
a
WARNING
ELECTRIC SHOCK
can
kill.

Always
wear
dry insulating gloves.

Insulate
yourself
from
work
and
ground.

Do
not
touch live
electrical
parts.

Keep
all
panels
and
covers
securely
in
place
FUMES
AND
GASES
can
be
hazardous
to
your
health.

Keep
your
head
out
of
the
fumes.

Ventilate
area,
or use
breathing
device.

Read
Material
Safety
Data Sheets
(MSDS5)
and
manufacturers instructions for material
used.
WELDING
can
cause
fire
or
explosion.

Do
not
weld
near
flammable
material.

Watch
for
fire;
keep
extinguisher nearby.

Do
not
locate
unit
over
combustible
surfaces.

Do
not
weld
on
closed
containers.

Allow
work and
equipment
to
cool
before
handling
ARCING
can
damage
switch.

Do
not
change Voltage
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
y
:9//,~
~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
S
Wear
welding
helmet
with
correct
shade
of filter.

Wear
correct
eye,
ear,
and
body
protection.
,~
~
e
MOVING
PARTS
can cause
injury.

Keep
away
from
pinch
points
such
as
drive rolls.

Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.

\
~
MAGNETIC FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker operation.

Pacemaker
wearers
keep
away.

Wearers
should consult
their
doctor before
going
near
arc
welding, gouging,
or
spot
welding
opera
tions.
WELDING CURRENT
can
damage
elec
tronic
parts
in
vehicles.

Disconnect
both
battery
cables before
welding
on a
vehicle.

Place
work
clamp
as
close
to
the
weld
as
possible.
See
Safety
Precautions
at
beginning
of manual
for
ba
sic
welding
safety
information.
swam6.2
8/92
Wear the
following
while
welding:
2 3
/
1
Dry,
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
With
Correct
Shade
Of Filter
(See
ANSI
Z49.1)
sb3.1
1/94
Figure
4-1.
Safety
Equipment
1
Wire
Mode
Switch
For
bettercontrol
of
wire
speed
use
Low
position
when
wire
speed
is
between
90 and
670
1pm.
Use Full
position
when
wire
speed
is be
tween
150
1pm
and
1030
ipm.
2
Voltage
Range
Selector
Place switch
in
desired
position.
See
inside
rear
cover
for
settings.
Ref. ST-i
53
874-B
/
S-i
71
601
Figure
4-2.
Center
Baffle
Controls
OM-157
066
Page
10

Tools Needed:
Figure
4-3. Front Panel Controls
1 Wire
Speed
Control
Use control
to set
wire
feed
speed.
2
Voltage
Control
Use control
and
Voltage
Range
Selector
(see
Figure
4-2)
to set
arc
voltage.
Step
6
of
Low
range
and
Step
1
of
High
range
overlap.
3
Pilot
Light
4
Power
Switch
Use switch
to turn
unit On and Oft.
The
pilot
light
comes
on
when unit
is turned
on.
5
Work
Clamp
Use wire
brush
or
sandpaper
to
clean metal
at
weld
joint
area.
Connect work
clamp
to
clean,
paint-free
location
on
workpiece,
as
close
as
possible
to
weld
area.
Ref. ST-i
54 622-B
/
ST-17i 639/Ref. ST-i
54251
1
2
OM-157
066
Page
11

SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC SHOCK
can
kill.

Do
not
touch live
electrical
parts.
Turn
Oft
welding
power
source,
and disconnect
input
power
before
inspecting, maintaining,
or
servicing.
HOT
PARTS
can
cause severe
burns.

Allow
cooling
period
before
maintaining
or
servicing.
5-1.
Routine Maintenance

41b
M


OVING
PARTS
can cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive rolls.
*~
Maintenance
and
troubleshooting
to
be
performed
only by
qualified
persons.
swam8 2* 2/93
Turn Off
all
power
before
maintaining.
Figure
5-1.
Maintenance Schedule
OM-157 066
Page
12

5-2.
Overload
Protection
READ
Sectio
SAFETY
n
5
befor
BLOCKS
at
start
of
e
proceeding.
A.
Circuit Br eaker
CB1
1
I
4?
~
1
Circuit Breaker
CB1
If
CB1
opens,
wire
feed
stops.
Check
gun
liner
for
blockage
or
binding
drive
gear,
or
misaligned
dnve
rolls. Allow
a
cooling period
before
resetting
CB1.
kinks,
and check for
jammed
wire,
Ref. ST-153
874-B
Figure
5-2.
Circuit Breaker
CB1
B.
Fuses
Fl And F2
Turn
Off
unit
and
disconnect
input
power.
1
Fuse
Fl
(See
Parts
List For
Rating)
Fl
protects
the
115
volts
ac
wind
ing
of
transformer Ti.
If Fl
opens,
all
weld
output
stops
and
pilot
light
PL1
goes
out.
2
Fuse
F2
(See
Parts
List For
Rating)
F2
protects
the
24
volts
ac
winding
of
transformer
Ti.
If
F2
opens,
all
weld
output stops.
Ref. ST-800 928-B
C.
Overheating
Figure
5-3. Fuse
Location
Figure
5-4.
Overheating
OM-157
066
Page
13

5-3.
Wire Drive
Assembly
Maintenance
____
READ
SAFETY
BLOCKS
at start
of
Section
5
before
proceeding.
Figure
5-5.
Wire
Drive
Assembly
Maintenance
Turn Off
unit
and disconnect
input
power.
Ref. ST-i
54
626-B / SA-145
763
/
ST-154
633
1
Wire
Spool
2
Gun
Contact
Tip
Cut
welding
wire
off
at contact
tip.
Retract
wire
onto
spool
and
Se-
cure.
3 Drive Roll
Alignment
Bolt
Turn in
or
out
until
groove
lines
up
with wire
guide.
4
Drive
Roll
5
Wire Inlet
Guide
Remove
guide
by
pressing
on
barbed
area or
cutting
off
one
end
near
housing
and
pulling
it
out
of
hole. Push
new
guide
into
hole
from
rear
until
it
snaps
in
place.
6
Pressure Roll Am,
7
Cotter
Pin
8 Pin
9
Screw
10
Bearing
Remove
bearing
as
shown. Install
new
bearing
and
secure
with
screw.
Reinstall
arm
onto
pin
and
secure
with
cotter
pin.
Thread
welding
wire
(see
Section
3-7).
Close
door.
Tools
Needed:
OM-157
066
Page
14